Are you like me and can’t help but give everywhere a rating even though it’s not where you would expect? You’ll find no five star restaurants with shabby or dirty toilets and you’ll find no high level successful business blocks with stained or old water closets. Indeed, even upon visiting a friend’s house for the first time, we rate places on the level of their bathrooms. I think everyone would agree, when it comes to sanitation we want our bathrooms to be cleaner than a surgeon’s theatre and more stylish than the Sidney Opera House.
Since 1946 Vaal Sanitaryware have been producing a continually changing and improving range of ceramic sanitary products to fit the needs of the sophisticated and discerning customer. Donnie Rust speaks with Sales Director Robin Koen regarding it. “It must be durable, comfortable and be aesthetically appealing,” Vaal’s is a promise of quality assurance and their spectacular range of basins, bidets and toilets represent the successful culmination of years of research and development. They understand the industry that they’re working in completely. “Not only do we comply with SABS and numerous international standards,” Robin explains, “But we conduct extensive research into the field of water-saving W.C.’s.” This has culminating in the development of a 4,5 litre flushing cistern, and 6/3 litre dual-flush cisterns. Such innovations are hardly surprising when they pertain to such a focus on cost effective reliability and are able to fall back on their invaluable experience in fulfilling large complex contracts. Employee training is something taken very seriously in an industry where their products are scrutinized so readily. From the manufacturers to the installers everyone is properly prepared to conduct their work at the very top of their game. “We offer full plumber training facilities,” Robin continues, “To ensure that the installers are able to keep the effectiveness on the same level as the style.” The process to develop such a wide product range, begins with the new designs being originated by marketing and sales in conjunction with manufacturing and a model is designed by one of their modellers, after a series of checks a block mould is produced in clay or china to check for any faults or design flaws and these can be measured and corrected at this stage. A master mould is then put together. High pressure casting machines use resin moulds, which are cast continuously 24/7. All bench and battery cast moulds used in manufacturing in the sanitaryware industry are
Endeavour Magazine • November 2012 •
Perspex SA is the leading supplier of Premium Sanitary Ware Grade Cast Acrylic Perspex. We would like to share a few reasons why: • All Perspex baths carry a 10-year warrantee • Excellent heat retaining properties, for a long, luxurious bath experience • Long life span - you’ll redo your bathroom before you need to buy a new bath! • High resistance to long term yellowing • Perspex baths are low maintenance with a superior gloss finish
We use only the best, We use Perspex. |
e only the best, e Perspex.
made from plaster of paris as this material is malleable and absorbent. In the factory a combination of high pressure, battery and bench casting is used. After completion of this casting process, a layer of clay is left on the inside face of the mould. Surplus slip is then drained away from the mould and returned to the storage tanks and the remaining mould is allowed to dry. Before inspection, it is important to ensure that each piece of sanitaryware has been correctly manufactured. This responsibility falls to the clay inspection team to examine each piece and to rectify any minor faults that may be apparent. “This is a most important section of the factory, as any ware that may be sub-standard that slips through this department without rectification will probably be a reject piece after firing.” Robotic & manual glazing methods are used to apply up to four layers of glaze. Careful consideration has to be applied to ensure there is no rippling. Their glaze consists of minerals: zircon, flespar, quartz, calcite, kaolin, zinc oxide. After glazing, the ware is placed onto storage tanks adjacent to the kilns. Vaal Sanitaryware use shuttle kilns, gas-fired tunnel kilns and top hat kilns. The kiln runs 24 hours a day as it is uneconomical to switch these kilns off and on to suit market requirements. Therefor the pipeline of projects must always be heavy on the top end. This kiln is capable of firing approximately fifteen and a half thousand pieces of vitreous
china per week. The temperature variation across the setting load is no more than 5Â°C and the maximum temperature of the kiln is approximately 1250Â°C. This process is controlled by automatic micro-processors which is better for health and safety and more efficient. After firing, each individual piece of ware is quality checked. All ware that passes the stringent quality requirements is passed to the stockyard while any that are not of the correct standard are either reprocessed or destroyed. Not merely satisfied with being the leader in quality Vaal Sanitaryware embrace a high regard for practically and in 2010 teamed up with the Quadriplegic and Paraplegic Association of South Africa (QASA) to extend their innovation and create a practical, yet aesthetically pleasing bathroom solution. In 2009 QASA members and Vaal embarked on a year long project aimed at establishing exactly what practical hindrances afflict quadriplegic and paraplegic individuals where bathroom facilities are concerned. Vaal aimed at designing, developing and testing a new bathroom solution that would significantly aid disabled individuals to complete routine tasks in a more efficient and safe manner. The result is a fully developed semi close coupled toilet that manages to take into account practicality while infusing it with style in an aesthetically pleasing design. The specially designed quad-para unit now exists under the name Pearl. Vaal Sanitarywareâ€™s success comes clearly from a stringent strategy of planning and design, followed by careful execution and a process of scrutinizing the results. For them there is only one standard that is applicable.
G&W Mineral Resources, established in 1951, is a member of the Zimco Group of companies in South Africa, which is a subsidiary of Eco-Bat Technologies in the United Kingdom. G&W is a supplier of quality industrial minerals from Matsopa mines, a subsidiary of G&W Mineral Resources. Products are Bentonite, Kaolin, Ceramic Clays, Talc, Attapulgite and many more .
Vaal Sanitaryware www.dawnltd.co.za +27 16 360 6000 Written by Donnie Rust